SSI New Generation DFSS Case Study

DFSS Case Study
Development Of A Robust Keypad

Project Summary
Client: Large Telecommunication Equipment Manufacturer

Challenge: Design of a Robust Key Pad
Goal:
•Reduce generic contact problem: Target < 0,5%
•Reduce total cost of the system: Target > 50%
•Increase the click ratio (feeling): Target > 25%
Results:
Following Results achieved due to DFSS implementation:
•Project Savings > € 3,000,000
•Generic contact problem: Actual ~ 0
•Total cost reduction of the system: Actual > 75%
•Increase the click ratio (feeling): Actual > 40%
•Reduction in design Cycle Time: 1 months IDOV
Page 1
Identify
•Project goals and objectives identified

•All Critical To Satisfaction elements collected through Voice Of the
Customer (VOC) process
•Project team assembled and project plan created
IDOV
Page 2
Identify
•Detailed analysis of the existing Design and its failure modes

•Analysis of Functional Requirements and Design Parameters
1. The key will be pushed down to the rocking 2. Before clicking down the polydomefoil, the
point silicone key will be compressed
IDOV
Page 3
Identify
•Detailed analysis of the existing Design and its failure modes

•Analysis of Functional Requirements and Design Parameters
3. After the abrupt click down of the polydome foil, 4. After this click feeling, usually customer will not push
the carbon coated inside of the polydome is the key anymore, and if at this moment the carbon
contacting the carbon meander on the printed meander on the printed circuit board is not short
circuit board, genearating a short circuit circuited, then a contact failure will happen. If some
additional force is applied, the carbon meander on the
printed circuit will be short circuited, which is the
unwanted situation
Page 4
Identify
Quantifying and measuring of the CTS after completed MSA (Measurement

System Analysis):
force diagram resistance diagram
shift “X” = bad function

X
F2
IDOV
Page 5
Design
Flow Down And Uncouple/Decouple
Constraints Constraints
Deliverytime,
Deliverytime,Cost
Cost Deliverytime,
Deliverytime,Cost
Cost
Customer Domain Physical Domain Process Domain
Generate Concepts Generate Concepts
Voice Of the
Customer (VOC) Evaluate Evaluate
(Customer Concepts Concepts
Requirements (Y)
Input Input Input
Disturbance Disturbance
(Noise, Coupling) (Noise, Coupling)
Functional Design Design Process Process

Requirements Transfer Variables Transfer Variables
{FR} Matrix {DV} Matrix {PV}
{FR} = [ D ]{DV } {DV } = [ P]{PV }

IDOV
Page 6
Design
{Y} = [I ]{FR}
{FR} = [D]{DV}
{Y } = [ F ]{ X }
{DV} = [P]{PV}
[I] = Unity Matrix
[P] = Process Transfer Matrix
{Y} = [I][P][D]{PV}
[D] = Design Transfer Matrix
[F] = System Transfer Matrix
1424 3 [FR] = Functional Requirements
[F ] {DV } = Design Variables
(Inputs, Control Parameters)
{PV } = Process Variables
(Inputs, Control Parameters)
{Y} = Customer Requirement (CR) IDOV
Page 7
Design
•Transferring Customer Attributes to Keypad Design Functions

Y1 : To be able to dial and send SMS to different persons (Spoken, Performance)
Y2 : To be able to notice the dialing (unspoken, must-be)
Y3 : Quick access to telephone functions (unspoken, excitement)
Y4 : Nice actuation of keys (unspoken, must-be)
Y5 : To be able to transportation in trouser pocket/bag etc. (unspoken, must-be)
Y6 : T be able to dial despite rainy days (unspoken, must-be)
Y7 : Cool printing on keys (Spoken, Performance)

⎧Y 1 ⎫ ⎡1 0 0 0 0 0 0 ⎤ ⎧ F D1 ⎫
⎪Y 2 ⎪ ⎢0 1 0 0 0 0 0 ⎥⎥ ⎪⎪ F D 2 ⎪⎪
FD1 : Provide Dialing/Writing
⎪ ⎪ ⎢
FD2 : Provide Dialing Signal ⎪Y 3 ⎪ ⎢0 0 1 0 0 0 0 ⎥ ⎪ FD 3 ⎪
⎪ ⎪ ⎢ ⎥⎪ ⎪
FD3 : Provide Navigation ⎨Y 4 ⎬ = ⎢0 0 0 1 0 0 0 ⎥ ⎨ FD 4 ⎬
FD4 : Prevent Key Stucking (%) ⎪Y 5 ⎪ ⎢0 0 0 0 1 0 0 ⎥ ⎪ FD 5 ⎪
⎪ ⎪ ⎢ ⎥⎪ ⎪
FD5 : Provide Dust Protection (Norm)
⎪Y 6 ⎪ ⎢0 0 0 0 0 1 0 ⎥ ⎪ FD 6 ⎪
⎪Y 7 ⎪ ⎢ ⎪ ⎪
FD6 : Provide Spray Water Protection (Norm)
⎩ ⎭ ⎣0 0 0 0 0 0 1 ⎥⎦ ⎩ F D 7 ⎭
FD7 : Provide 3D Surface Printing
IDOV
Page 8
Design
•Transferring Keypad Design Functions to Design Variables

FD1 : Provide Dialing X D1 : Actuating Keypad System
FD11 FD12 FD13 X D11 X D12 X D13

Transformation Snapping Contact on PCB Actuator Polydome Carbon PCB /
of a mechanical (Click Feeling) (< 300 Ohm, Contact > 99 %) Polydome
linear movement (F min at x min)
to displacement
FD111 FD121 FD131 XD111-1 XD111-2 XD121-1 XD121-2 XD131-1 XD131-2

F max F min < 300 Ohm Silicon Web Thickness Diameter Type Pitch
Hardness Design
FD112 FD122 FD132 XD112 XD122 XD132

@ Displacement x max @ Displacement x min > 99 % Plunger Height Plunger
Height Diameter
IDOV
Page 9
Design

Hierarchy 1
FD2 : Dialing Signal X D2 : Audio Signal (Original Design : Speaker)
FD3 : Navigation X D3 : Navigation Key
FD4 : Key Stucking (%) X D4 : Key Gap
FD5 : Dust Protection (Norm) X D5 : Dust Sealing
FD6 : Spray Water Protection (Norm) X D5 : Water Sealing
FD7 : 3D Surface Printing X D7 : Tampon Print
⎧ F D1 ⎫ ⎡ A11 0 0 0 0 0 0 ⎤ ⎧ X D1 ⎫ Design Variables XD1, XD2 are integrated

⎪ FD 2 ⎪ ⎢ 0
⎪ ⎪ ⎢ A 22 0 0 0 0 0 ⎥⎥ ⎪⎪ X D 2 ⎪⎪ in the same physical area (New Design :Actuator)
to reduce the complexity
⎪ FD 3 ⎪ ⎢ 0 0 A33 0 0 0 0 ⎥ ⎪ XD 3 ⎪
⎪ ⎪ ⎢ ⎥⎪ ⎪
⎨ FD 4 ⎬ = ⎢ 0 0 0 A 44 0 0 0 ⎥ ⎨ XD 4 ⎬
⎪ FD 5 ⎪ ⎢ 0 0 0 0 A55 0 0 ⎥ ⎪ XD 5 ⎪ Design Variables XD5, XD6 are integrated
⎪ ⎪ ⎢ ⎥⎪ ⎪ in the same physical area
⎪ FD 6 ⎪ ⎢ 0 0 0 0 0 A66 0 ⎥ ⎪ XD 6 ⎪ (New Design :Polydome foil sticked on PCB)
⎪ FD 7 ⎪ ⎢ ⎪ ⎪
⎩ ⎭ ⎣ 0 0 0 0 0 0 A77 ⎥⎦ ⎩ X D 7 ⎭ to reduce the complexity
IDOV
Page 10
Design

Hierarchy 2
⎧ F D11 ⎫ ⎡ A11 0 0 ⎤ ⎧ X D11 ⎫

⎪ ⎪ ⎢ ⎪ ⎪
⎨ F D12 ⎬ = ⎢ 0 A 22 0 ⎥⎥ ⎨ X D12 ⎬ Independency of Design Functions
Uncoupled Design Transfer Matrix
⎪ F D13 ⎪ ⎢ 0 A33 ⎥⎦ ⎪⎩ X D13 ⎪⎭
⎩ ⎭ ⎣ 0
IDOV
Page 11
Design

Hierarchy 3
⎧ X D111 − 1 ⎫
⎪ X D111 − 2 ⎪
⎧ F D111 ⎫ ⎡ A11 A12 0 0 0 0 0 0 0 ⎤⎪ ⎪
⎪ F D112 ⎪ ⎢ 0 ⎪ X D112 ⎪
⎪ ⎪ ⎢ 0 A 23 0 0 0 0 0 0 ⎥⎥ ⎪ ⎪
⎪ X D121 − 1 ⎪
⎪⎪ F D121 ⎪⎪ ⎢ 0 0 0 A34 A35 0 0 0 0 ⎥⎪ ⎪
⎨ ⎬=⎢ ⎥ ⎨ X D121 − 2 ⎬
F ⎪ ⎢ 0 0 0 0 0 A 46 0 0 0 ⎥⎪
⎪ X D122 ⎪
D122
⎪ F D131 ⎪ ⎢ 0 0 0 0 0 0 A57 A58 0 ⎥⎪ ⎪

⎪ ⎪ ⎢ ⎥ ⎪ X D131 − 1 ⎪
⎪⎩ F D132 ⎪⎭ ⎢⎣ 0 0 0 0 0 0 0 0 A69 ⎥⎦ ⎪ ⎪
⎪ X D131 − 2
⎪
⎪⎩ X D132 ⎪⎭
Redundant Design Variables

Coupled Design Transfer Matrix but the Sensitivities will be checked experimentely
IDOV
Page 12
Design
Concept Generation & Selection
Concept Generation, Selection, and Feasibility using

structured methodologies:
IDOV
Page 13
Design
Preliminary Design
Not critical key height (less compression) Critical key height (high compression)
Old System New System
Inexpensive graphite meander on the new PCB

Expensive gold meander on the old system
PCB system
Difficult to contact because of the min. pitch
Easier to contact because of the min. pitch (technology limitation) and high contact
and low contact resistance of gold resistance IDOV
Page 14
Design
Detailed Design
Hardcap
Silicone
Polydomfoil
Spacerfoil
IDOV
Page 15
Design
Functional Block Diagramming
•Function Block & P-Diagramming
Noise Factors
Compression Snap-In
Output Signal Output Signal
Input Signal : Linear F (Functional F (Functional
Mechanical Movement Requirement) : Requirement) :
F max
F max at x max F min at x min
1
F min
β
x x
x max x min
Control Factors
(Design Parameters)
Silicon Plunger Polydome Polydome

Hardness Height Hight Thickness
Web Polydome
Design Diameter
Project Boundry
(Projekt Focus)
Page 16
Design
Functional Block Diagramming
•Function Block & P-Diagramming
Noise Factors
Force to Signal Converter Electric to
(Key Contact on PCB Meander) Time Delay Acoustic Converter
Output Signal Output Signal
Input Signal : F Short on Meander (Functional
F min at x min (< 300 Ohm, 99%) Requirement) :
F max
Audio Signal
1
x
x max
Control Factors
(Design Parameters)
Carbon Type Plunger

Diameter
Carbon
Meander
Pitch
Project Boundry
(Projekt Focus)
Page 17
Design
Robustness
Noise Factors
Make the Design robust to noise factors.
Control Factors
IDOV
Page 18
Noise Factor Effect
(Function Dialkeys)
Main Effects Plot for Means
Operator Device Act.Directio

149
147
Mean
145
143
141
er t
g le
n
1 2 rt. riz.
S aa ue Ve
H
o
B
CNF2 (Compoung Noise Factor 2) = Op1 + Device 1 + Actuator Direc. Vertical
CNF1 (Compound Noise Factor 1) = Op 1 + Device 2 + Actuator Direc. Horizontal
IDOV
Page 19
Control Factor Effect for S/N Ratio
Function Dialkeys
Main Effects Plot for S/N Ratios
PCB Pitch Plunger Dia Spacer PET Dome Dia Dome Shape
48,0
45,5
S/N Ratio
43,0
40,5
38,0
l
6 8 E 75u 0u 00u 5u mm m rma t
0, 0, D 5
1 1 2
1 5 6m no f la
= Control Factor Levels already implemented in design

IDOV
Page 20
Control Factor Effect for Means
Function Dialkeys
PCB Pitch Plunger Dia Spacer PET Dome Dia Dome Shape
280
240
Mean
200
160
120
0,
6
0,
8 D E u 0u 00u 5u mm m al fla
t
75 15 1 12 5 6m norm
IDOV
Page 21
Design
Transfer Functions
Utilize Design of Experiments to create transfer functions

A B C D E F
0,6 E 75u 100u 5mm normal
0,6 E 75u 125u 6mm flat
0,6 D 150u 100u 5mm flat
0,6 D 150u 125u 6mm normal
0,8 E 150u 100u 6mm normal
0,8 E 150u 125u 5mm flat
0,8 D 75u 100u 6mm flat
0,8 D 75u 125u 5mm normal
First rough samples with holes in

the plungers to increase the Main Effects Plot for Means
contact area and forces
A B C D E F
220
190
160
Mean
130
100
0,
6
0,
8 D E
75
u 0u 0u 5u m m al fl a
t
IDOV
15 10 12 5m 6m rm
no
Page 22
Design
Correction of Transfer Matrix

FD1 : Dialing X D1 : Actuating Keypad System
FD11 FD12 FD13 X D11 X D12 X D13

Transformation Snapping Contact on PCB Actuator Polydome Carbon PCB /
of a mechanical (Click Feeling) (< 300 Ohm, Contact > 99 %) Polydome
linear movement (F min at x min)
to displacement
FD111 FD121 FD131 XD111-1 XD111 XD121-1 XD121-2 XD131 XD131-2

F max F min < 300 Ohm Silicon Web Thickness Diameter Type Pitch
Hardness Design
XD121
Plunger
Hole Depth
FD112 FD122 FD132 XD112 XD122 XD132

@ Displacement x max @ Displacement x min > 99 % Plunger Height Plunger
Height Diameter
Design Variables fixed to
a choosed value XD132
Plunger
Patent Pending Hole Dia.
IDOV
Page 23
Design
•Correction of Design Transfer Matrix

Hierarchy 3
⎧ F D111 ⎫ ⎡ A11 0 0 0 0 0 ⎤ ⎧ X D111 ⎫

⎪ F D112 ⎪ ⎢ 0 A 22 0 0 0 0 ⎥⎥ ⎪⎪ X D112 ⎪⎪
⎪ ⎪ ⎢
⎪⎪ F D121 ⎪⎪ ⎢ 0 0 A303 0 0 0 ⎥ ⎪⎪ X D121 ⎪⎪
⎨ ⎬=⎢ ⎥⎨ ⎬
⎪ F D122
⎪ ⎢ 0 0 0 A 44 0 0 ⎥ ⎪ X D122 ⎪ Design Variables introduced
⎪ F D131 ⎪ ⎢ 0 0 0 0 A55 0 ⎥ ⎪ X D131 ⎪ in same physical area
⎪ ⎪ ⎢ ⎥⎪ ⎪
⎪⎩ F D132 ⎪⎭ ⎢⎣ 0 0 0 0 0 A66 ⎥⎦ ⎪⎩ X D132 ⎪⎭
Uncoupled Design Transfer Matrix
IDOV
Page 24
Design
•Transferring Keypad Design Variables to Process Variables Hierarchy 3
XD111 : Web Design X P112 : Insert 1
XD112 : Plunger Height X P112 : Insert 2
XD121 : Plunger Hole Depth X P112 : Insert 3
XD122 : Polydome Height X P1221 : Temperature

X P1222 : Cycle-Time
X P1223 : Pressure
XD131 : Carbon Type X P131 : Temperature
XD132 : Plunger Hole Diameter X P132 : Insert 4
IDOV
Page 25
Design
Transfer Functions
•Checking design parameter to process variable relation and fixing

redundant process variables (cycle time, pressure) to obtain robust
parameter XD122
Polydome Height Polydome Height
Temperature Cycletime Pressure Temperature Cycletime Pressure

74.0
37.20
71.5
36.95
S/N Ratio
Mean
69.0 36.70
36.45
66.5
36.20
64.0
0 0 0 5 7 9 6 7
0 0 0 5 7 9 6 7
11 12 14 15 11
12 14 15
IDOV
Page 26
Design
•Transferring Keypad Design Variables to Process Variables Hierarchy 3
XD111 : Web Design X P112 : Insert 1
XD112 : Plunger Height X P112 : Insert 2
XD121 : Plunger Hole Depth X P112 : Insert 3
XD122 : Polydome Height X P1221 : Temperature

X P1222 : Cycle-Time
Process Variables fixed to
X P1223 : Pressure a choosed value
XD131 : Carbon Type X P131 : Temperature
XD132 : Plunger Hole Diameter X P132 : Insert 4
IDOV
Page 27
Optimization
Surface Plot of C NS
quantifying of the optimum

functionality of the dialkey 8
C NS 5
4
Surface Plot of Q D4 3 1,6
1,,5
1,4
1,3
2,
2,5 1,2 Z
1,1
1 1
3,0 1,0
X 3,5
350
300
Q D4 250
1,,5
1,6 quantifying of the optimum
200
1,4
1,3
Z
2,
2,5
3,0 1,0
1,1
1,2
volume of noise of the Navikey
X 3,5
IDOV
Page 28
Optimization
IDOV
Page 29
Control Factors for Taguchi DOE
• We will focus to change the keypad plunger design to enlarge the contact area
• The following factors will be defined with 3 levels as controllable factors
Hol e dept h
Hol e di amet er
Pl unger di amet er
Pl unger Di st ance
IDOV
Page 30
Taguchi DOE Analysis for Noise Factors
customer case Contact poin

294
293
Mean
292
291
290
r ou A B ak
ee de
Pi Zh Pe Si
IDOV
Page 31
Taguchi DOE Analysis for Control Factors
• Analysis result:
Main Effects Plot for Means of left key inside

Main Effects Plot for S/NRatios of left key inside
Actuator Offset Plung Web Thicknes Plunger Slan Actuator Offset Plung Web Thicknes Plunger Slan
300
49.2
280
48.4
S/N Ratio
Mean
260
47.6
240
46.8
46.0 220
0 6 0 6
1.
2 .2 1* 0.
1 A .1 20 27 35 12 1.
2 .2 1* 0.
1 A .1 20 27 35 12
*1 1. A- +0 0. 0. 0. *1 1. A- +0 0. 0. 0.
6* .9 5* 6* .9 5*
2. *1 2. A 2. *1 2. A
4* 3 4* 3
3. 3.
• After cross-functional discussion with Suppliers, the following parameter will be used in verify phase
for the confirmation run:
IDOV
Page 32
Validate
Quantifying and measurement of CTS after project completion:

Resistance
Force
no shift = good function
IDOV
Resistance Displacement
Page 33
Validate
Validate the Design using Life Cycle Tests
Version: New Keypad System
Number of samples: 2x2 pcs/cavity
Number of hits: 200.000

testing cycles: Force-Stroke-Measurement
50.000 times --> F/s diagram OK

Testing result:
No. of cycles 4 7 8 15
0 9 9 9 9
50.000 ? ? ? ?
100.000 ? ? ? ?
150.000 4 cracks 9 9 9
at cavity 4 only the navi-key was damaged
IDOV
Page 34
Project Results
•Time frame: Target 4 months, achieved 3 months

•Generic contact problem: Target < 0,5%, achieved almost 0
•Reduce total cost of the system: Target > 50%, achieved > 75%
•Increase the click ratio (feeling): Target > 25%, achieved > 40%
•Savings due to achieved results > 3 Million Euro
•Development Cycle Time reduction for the next product generation because
of the cancelled second iteration with soft tools
•Same keypad system implemented in all the families of the existing and the
next product generation
•Patent Application for: “Polydomfoil Keypad with Optimized actuators”
Page 35
SSI - Six Sigma & Innovation
Josef-Fehler-Str. 43
46397 Bocholt
Fon: +49 2871 2745565

Fax: +49 2871 2745564
Mobil: +49 173 2856431
E-Mail: byurdakul@ssi-team.com
http://www.ssi-team.com
The following are trademarks and service marks of SSI, Six Sigma & Innovation: New Generation Design For Six Sigma ®, Quick Improvement Projects ®, Six Sigma Light ®
Six Sigma is a federally registered trademark of Motorola, Inc. MINITAB is a federally registered trademark of Minitab, Inc.
Page 36

SSI New Generation DFSS Case Study

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DFSS Case Study

Development Of A Robust Keypad

Client: Large Telecommunication Equipment Manufacturer

•Project goals and objectives identified

•Detailed analysis of the existing Design and its failure modes

•Detailed analysis of the existing Design and its failure modes

Quantifying and measuring of the CTS after completed MSA (Measurement

force diagram resistance diagram

shift “X” = bad function

Generate Concepts Generate Concepts

Input Input Input

Functional Design Design Process Process

{FR} = [ D ]{DV } {DV } = [ P]{PV }

•Transferring Customer Attributes to Keypad Design Functions

Y2 : To be able to notice the dialing (unspoken, must-be)

Y3 : Quick access to telephone functions (unspoken, excitement)

Y4 : Nice actuation of keys (unspoken, must-be)

Y5 : To be able to transportation in trouser pocket/bag etc. (unspoken, must-be)

Y6 : T be able to dial despite rainy days (unspoken, must-be)

Y7 : Cool printing on keys (Spoken, Performance)

•Transferring Keypad Design Functions to Design Variables

FD11 FD12 FD13 X D11 X D12 X D13

FD111 FD121 FD131 XD111-1 XD111-2 XD121-1 XD121-2 XD131-1 XD131-2

FD112 FD122 FD132 XD112 XD122 XD132

•Transferring Keypad Design Functions to Design Variables

FD4 : Key Stucking (%) X D4 : Key Gap

FD5 : Dust Protection (Norm) X D5 : Dust Sealing

FD6 : Spray Water Protection (Norm) X D5 : Water Sealing

FD7 : 3D Surface Printing X D7 : Tampon Print

⎧ F D1 ⎫ ⎡ A11 0 0 0 0 0 0 ⎤ ⎧ X D1 ⎫ Design Variables XD1, XD2 are integrated

•Transferring Keypad Design Functions to Design Variables

⎧ F D11 ⎫ ⎡ A11 0 0 ⎤ ⎧ X D11 ⎫

•Transferring Keypad Design Functions to Design Variables

⎪ F D131 ⎪ ⎢ 0 0 0 0 0 0 A57 A58 0 ⎥⎪ ⎪

Redundant Design Variables

Concept Generation, Selection, and Feasibility using

Old System New System

Inexpensive graphite meander on the new PCB

•Function Block & P-Diagramming

Silicon Plunger Polydome Polydome

•Function Block & P-Diagramming

Carbon Type Plunger

Make the Design robust to noise factors.

Operator Device Act.Directio

= Control Factor Levels already implemented in design

Main Effects Plot for Means

Utilize Design of Experiments to create transfer functions

First rough samples with holes in

•Transferring Keypad Design Functions to Design Variables

FD11 FD12 FD13 X D11 X D12 X D13

FD111 FD121 FD131 XD111-1 XD111 XD121-1 XD121-2 XD131 XD131-2

FD112 FD122 FD132 XD112 XD122 XD132

•Correction of Design Transfer Matrix

⎧ F D111 ⎫ ⎡ A11 0 0 0 0 0 ⎤ ⎧ X D111 ⎫

Uncoupled Design Transfer Matrix

•Transferring Keypad Design Variables to Process Variables Hierarchy 3

XD111 : Web Design X P112 : Insert 1

XD112 : Plunger Height X P112 : Insert 2

XD121 : Plunger Hole Depth X P112 : Insert 3

XD122 : Polydome Height X P1221 : Temperature

XD131 : Carbon Type X P131 : Temperature

XD132 : Plunger Hole Diameter X P132 : Insert 4

•Checking design parameter to process variable relation and fixing

Polydome Height Polydome Height